Pressed Tube Coupling Element for Low-Cost Leadscrew Attachment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing coupling elements for threaded spindles in motor vehicle steering columns are costly to produce and require complex manufacturing processes, limiting their efficiency and flexibility.
Innovation Solution
A coupling element is designed using a hollow cylindrical pipe section that is plastically deformed to form a flat pressing section, allowing for a one-piece construction without deforming the threaded spindle, which reduces production costs and effort, and can be adapted to different materials and designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a coupling element is produced using traditional manufacturing processes, then the structural integrity and strength are ensured, but the production cost increases and manufacturing complexity increases
Solution Approach 1:
The coupling element is formed as a one-piece component by plastic deformation of a tube section, merging the coupling body and coupling arm into a single integrated structure. This eliminates the need for separate manufacturing and assembly of multiple parts, reducing production cost and manufacturing complexity while maintaining structural integrity
Solution Approach 2:
The invention uses plastic deformation to change the physical state and shape of the tube section, transforming it from a cylindrical form to the final coupling element geometry. This parameter change approach enables cost-effective manufacturing compared to traditional machining or molding processes
2Productivity
If a coupling element is produced using traditional manufacturing processes, then the structural integrity is ensured, but the production effort and time increase
Solution Approach 1:
The plastic deformation process enables rapid shaping of the coupling element from a simple tube section, significantly reducing production time compared to traditional manufacturing methods that require multiple machining or molding operations
Solution Approach 2:
The one-piece construction method combines multiple manufacturing operations into a single plastic deformation process, eliminating sequential manufacturing steps and associated setup times, thereby improving overall productivity
3Shape
If the threaded spindle is deformed to create the coupling element, then the coupling section can be formed, but the mass of the threaded spindle increases and the process becomes more complex
Solution Approach 1:
The invention extracts the coupling element formation process from the threaded spindle by using a separate tube section that is plastic-deformed into the coupling element shape. This separates the coupling section formation from the spindle mass, achieving the desired shape without unnecessarily increasing the overall mass
Solution Approach 2:
Plastic deformation of the tube section efficiently creates the coupling section shape with minimal material waste and added mass, compared to alternative methods that would require additional material or more complex forming processes
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables a more efficient and flexible manufacturing process, reducing the mass of the coupling element and allowing for easier adaptation to various designs, while maintaining a strong holding effect and safety features such as energy absorption in crashes.
Implementation Method 1
the coupling section has a press section in which the tube section is plastically squeezed flat transversely to the axis
Data Source
Figure 1~3
Figure 4~9
Figure 10~12
AI summary
The present invention relates to a coupling element (6) for attaching to a leadscrew (4), which coupling element has a receiving portion (61), which is formed as a single piece with a coupling portion (62), wherein the receiving portion (61) extends in the shape of a hollow cylinder along an axis (S), with an axial receiving opening for receiving the leadscrew (4), and the coupling portion (62) is flattened perpendicularly to the axis (S) relative to the receiving portion (61) and has a connecting means (63). In order to be able to produce a coupling element (6) more efficiently and more flexibly, according to the invention the receiving portion (61) and the coupling portion (62) are formed from a continuous, integral pipe piece, the coupling portion (62) having a pressed portion (62), in which the pipe piece is plastically squeezed flat perpendicularly to the axis (S).